Tom's of Maine sells $19 million worth of personal care products annually from its 8-sq-ft refurbished railroad freight building in Kennebunk ME. All products are filled on two lines within a packaging area that occupies a scant 3 sq ft. Until about two years ago space limitations slowed production to a crawl on stick deodorants. They're filled on Tom's liquid filling line that also accommodates mouthwash shampoo soap and shaving cream. Deodorant sticks filled at temperatures around 125°F proved especially troublesome to cool. And there's the rub. "We wanted to cool the product in line" recalls Gary Rittershaus Tom's vp of manufacturing "but the traditional method of cooling stick deodorant by running it along massive lengths of conveyor through air-conditioned rooms wouldn't work because we didn't have the space to do it." Instead the molten deodorant-filled containers were manually removed from the line and placed on 3' x 2' carts then rolled away from the line consuming valuable floorspace. After cooling in the ambient air containers were repositioned on the line for capping and labeling. "That process required a lot of labor and we had unbelievable spillage" Rittershaus notes. "We had to pull off those deodorant containers wipe them down then put them back on the line. Our rework rate was somewhere between five and six percent." The manual procedure limited production rates to a mere 35 containers/min. A change was in order. Tom's considered dry ice but turned to an even colder alternative: a chiller from Liquid Carbonic (Oak Brook IL) that uses liquid nitrogen in vapor form to quickly cool the deodorant in line. Since adding the chiller Rittershaus says production rates have reached 65/min. The increase is attributable to eliminating manual removal and replacement of the containers from the line. Workers now focus on downstream tasks that facilitate distribution and sales. What's more rework rates have plummeted to less than 1%.